Flexible translucent to transparent fireproof composite material

ABSTRACT

A fireproof, translucent, flexible coated fabric composite material for use in fire curtains. The composite material meets or exceeds regulatory requirements in terms of fire endurance and allows transmissivity of necessary amounts of light. The process of the present disclosure combines a silica fabric with a special refractory index controlled resin. This unique combination of materials can transform an opaque high temperature fabric into a translucent, and even transparent, composite which as the ability to resist high temperature, flame and smoke penetration that fills a needed gap in technology between visibility and fire resistance in the field of fire and smoke curtains used in civil construction.

BACKGROUND

The present disclosure generally relates to composite materials andmethod of manufacture thereof, and more specifically to translucent ortransparent composite materials that may be used in civil construction,non-fire penetration, and non-permeability to smoke.

Fireproof curtains or partitions are often used in civil constructionsettings between rooms and adjacent elevators. Fire curtains do notcontain windows, which makes determining whether hazardous conditionsexist behind the fire curtain difficult for firefighters. Currently,materials developed for fire and smoke curtains which provide both smokeand flame penetration resistance are not translucent or transparent.

Conventional materials used in fire curtains do not achieve thecombination of a desired transmissivity of light, while meetingregulatory requirements in terms of flammability resistance. As such,conventional fire curtains are opaque. In fire and smoke curtainapplications, materials such as polyamide and silicone films have beenused to eliminate smoke penetration but do not provide adequateprotection from flame penetration. Therefore, it is highly desirablethat fire curtains have translucent or transparent composite panelscomprised of translucent or transparent composite materials that offerprotection from high temperature fires.

Existing translucent or transparent composite materials can offerprotection from high temperature fires (see U.S. Pat. No. 5,552,466 andU.S. Patent App. Pub. No. 20100093242). However, due to their rigidityand other undesirable properties, these composite materials have notbeen utilized in fire curtains. Methods for manufacturing rigidtranslucent or transparent composite materials, which are used inapplication such as surfboard manufacturing, include combining anopaque, fine fiberglass fabric with a refractory index controlledacrylic resin that matches the refractory index (RI), or refractoryindex value, of the fiberglass substrate.

For a translucent or transparent composite material to be viable for usein fire curtains, it is necessary that it be flexible. It is alsodesirable that a flexible, translucent or transparent material below-cost in terms of manufacture and raw material costs. A translucentor transparent composite panel in a fire curtain must allow transmissionof enough visible light to ascertain conditions behind the curtain.

Accordingly, there is a need in the art for a translucent ortransparent, flexible fire curtain composite panel which can preventflame and smoke penetration.

SUMMARY

The present disclosure relates to translucent or transparent, flexibleand fireproof coated fabric composite materials for use in firecurtains. The composite material meets or exceeds regulatoryrequirements in terms of fire endurance and allows transmissivity ofnecessary amounts of light. The process of the present disclosurecombines a silica fabric with a special refractory index controlledresin. This unique combination of materials can transform an opaque hightemperature fabric into a translucent, and even transparent, compositewhich as the ability to resist high temperature, flame and smokepenetration that fills a needed gap in technology between visibility andfire resistance in the field of fire and smoke curtains used in civilconstruction.

In one embodiment of the present disclosure, the composite may compriseone or more layers of optically controlled silicone resin and highpurity silica fabric. The composite material is a three-layer system. Ina three-layer system, the impregnated silicone fabric is centeredbetween two layers of optically controlled silicone resin. The preferredmanufacturing processes identified for forming the three-layer compositepanel is a fabric impregnation process. The composite material may bepre-cut or may then be cut to the shape of the final composite panel.

In the present disclosure, silicone resins are used to treat the fabricsheet. Preferred resins are fabricated from silicone polymers such aspolydimethylsiloxane (PDMS) or polysiloxanes. Exemplary polymercompositions include NuSil™ LS6946. The treatment renders the normallyopaque fabric translucent to transparent, while enhancing the fireresistance of the coated fabric composite.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-sectional view of the layers of the composite panelof the present disclosure;

FIG. 2 is a flow diagram of the process of the present disclosure;

FIG. 3A is a front view of an opaque silica fabric sheet of the presentdisclosure;

FIG. 3B is a front view of a composite panel treated with an improperresin of outside of the viscosity range of the present disclosure;

FIG. 3C is a front view of a composite panel created using the processof the present disclosure;

FIG. 4 shows the ASTM E-119 temperature profile for measuring fireendurance;

FIG. 5 shows the chemical composition change from polysiloxane to silicaresulting from ceramification;

FIG. 6 shows composite panel 10 incorporated into a fire curtain 70.

DETAILED DESCRIPTION

The present disclosure describes various embodiments of a compositepanel and method for providing a translucent or transparent, flexible,and fireproof composite material with exceptional fire and smokeresistant properties. Flexibility may be defined herein as the abilityto be formed into a roll and extended into a sheet. According to anembodiment the composite panel of the present disclosure is a treatedand encapsulated silica fabric. The fabric silica sheet, prior to thetreatment of the present disclosure, is opaque, however, after treatmentaccording to the present disclosure, the sheet becomes translucent ortransparent.

The present disclosure describes the formation of composite materialsthat are ideally suited for use as translucent or transparent componentsfor fire curtain composite panels due to their light transmissivityproperties and flame retardancy. As one of ordinary skill wouldrecognize, however, the composite materials may be used in otherapplications not directly related to fire curtains. For example, thecomposite materials could find usage in other high temperatureenvironments such as industrial ovens and dryers.

The translucent or transparent composite panel of the present disclosuremeets regulatory authority certification requirements for fire curtains.

FIG. 1 shows a cross-sectional view of one embodiment the compositepanel 10 of the present disclosure. Outer layers of silicone resin 14surround a layer of composite panel impregnated silica fabric sheet 12.The composite panel impregnated silica fabric sheet 12 is impregnatedwith the silicone resin that ultimately forms the outer layers ofsilicone resin 14. Each outer layer is essentially extruded fromcomposite panel impregnated silica fabric sheet 12 during the process ofthe present disclosure. A basis weight of fabric sheet 32 is preferablybetween 180 and 600 gsm. Outer layers of silicone resin 14 are generallybetween 5 and 10 mm wide.

Non-limiting examples of components formed from the composite materialof the present disclosure include many fire-related applications such asfire curtains and doors visible light transmitting composite panels.

FIG. 2 is a flow diagram of the process 200 of the present disclosure.Optical silicone resin is prepared by pre-blending a two-part resinsystem. The properties of a preferred embodiment of a silicone resin areshown in Table 1. In the process of the present disclosure a firstsilicone resin 22 is combined with a solvent 20, to form a firstdispersant 26. A second silicone resin 24 is combined with the solvent20 to form a second dispersant 28. In a preferred embodiment, the firstsilicone resin 22 contains a catalytic ion which is a platinum-basedanionic catalyst and the second silicone resin 24 contains a catalyticion which is a platinum-based cationic catalyst. The silicone resin maybe, in a preferred embodiment, NuSil™ LS6946 Optically Clear siliconeresin (approximately 30 to 40 gm/sf). The silicone resin is, in thepresent disclosure, refractory index controlled. Shifts in the resin,depending on the refractive index (RI) value of the fabric, may rangefrom RI of 1.45 to 1.47. Introducing fumed or nano-silica to the resinmay optimize translucency. Mixing silica at different levels mayincrease the refractory index value such that the refractive index valuemay be 1.41 improved to 1.47 with optimal silica mixture.

The silicone resin should have an optical refractive index value matchto the silica fabric sheet, which may be in a range of 1.41 to 1.46.This will vary based on the purity of the silica fabric sheet, with 1.43being optimized for the preferred 92% silica fabric. For reference, 100%silica would be at 1.40 and a fabric sheet with a silica content of 50%would be optically transparent with a refractory index value of 1.51.

Use of optical silicone with an RI of 1.51 which is typical forfiberglass materials is not effective for the purposes of the presentdisclosure. The first silicone resin 22 and second silicone resin 24 arepreferably NUSIL™ LS6946 resins, which come with a first silicone resin22 and a second silicone resin 24 pre-blended with platinum-based ioniccatalysts. Catalysts comprising a platinum group metal (i.e., platinum,rhodium, ruthenium, palladium, osmium and iridium) or a compoundcontaining a platinum group metal may constitute alternatives toplatinum for the purposes of the present disclosure. Inorganiccatalysts, as opposed to organic catalysts, are important for thepresent disclosure due to the need for avoiding smoking or burning oforganic compounds during exposure to fire.

The resins used in the present disclosure are of high viscosity, atapproximately 50,000 centipoise. NUSIL™ LS6946 resin, and other resinsof high viscosity, were initially thought to be unacceptable as they aretoo viscous to be properly absorbed by a fabric in order to achievetranslucency.

The definitions of translucent, opaque and transparent, for the purposesof the present disclosure, are: material which has a total visible lighttransmission (VLT) of 85% or more is transparent; a VLT above 50% istranslucent; and a VLT below 50% is opaque. The translucent sheetproduced by the process of the present disclosure has a VLT generallybetween 65% and 80%, as measured by a set of light meters. The set oflight meters referred to herein is the standard means by which VLT ismeasured, as would be known to one of ordinary skill in the art.

The use of high viscosity resins at initially approximately 50,000centipoise (cps), or a range between 40,000-60,000 centipoise, isimportant for the process of the present disclosure. The initial highviscosity is necessary because high percentage of solids present in highviscosity resins are required to impart the desirable final propertiesto the composite panel. However, for the present disclosure, resinsneeded to be treated to lower the viscosity for proper wet-out. Toachieve proper wet-out, a solvent 20 is added to the initially highviscosity resin. Optimal viscosity for wet-out is between 8,000-10,000cps, which is critical to the disclosure. Initially lower viscositysilicone resins with the same Refractive Index (RI) as NUSIL™ LS6946were tested but did not produce acceptable results.

Low viscosity of the resin, when applied to a fabric sheet is criticalto composite wet-out, however, starting with lower viscosity materialreduces desirable properties necessary for the final product due to thelower percentage solids, thereby necessitating the modifications of thepresent disclosure. The present disclosure resolves the issue of theinitial viscosity being too high by addition of a solvent 20. In apreferred embodiment the solvent 20 is low sulfur xylene, which isimportant for the process of the present disclosure. Modifying the resinviscosity with low sulfur xylene at the appropriate levels resolvedproblems with viscosity, however these other solvents had negativeimpacts on the final product.

Low sulfur xylene is preferably added at a ratio of 4:1 resin to lowsulfur xylene, however, the range of 1:1 resin to low sulfur xylene atthe low end and 8:1 resin to low sulfur xylene at the high end mayproduce a functional product. The resin must be modified into the targetwet-out range by use of the special clear solvent 20, low sulfur xylene,at the proper dilution ratios and dispersant procedure. Numerous resinsat different viscosity were tested to discover the optimal range for thepresent disclosure. The process of the present disclosure requires theuse of silicone resin to produce appropriate fiber-reinforced polymers(FRP) whereas a silicone does not achieve the desired result. Theprocess of the present disclosure includes use of nano-silica functionalfiller. Nano-silica comes pre-blended with NUSIL LS6946 resin, whileother resins could be used and the nano-silica could be addedseparately.

As shown in FIG. 2, the first dispersant 26 and the second dispersant 28are combined to form combined silicone resin 30. Use of high viscosityresin and reducing its viscosity to an optimal range by pre-dispersingthe two components of the resin in a specifically defined solvent, at aspecific blend ratio, under a specifically defined method is critical inthe present disclosure.

Combined silicone resin 30 is measured to an appropriate amount forapplication to a fabric sheet 32, which is comprised of silica. A basisweight of the fabric sheet 32 is preferably between 180 and 600 gsm. Thefabric sheet may be leached, which is a known process in the art,however, the present disclosure requires identification of theappropriate starting material for the fabric sheet 32 which will allowit to be leached while maintaining the necessary strength for designateduse. The appropriate fabric sheet 32 is an opaque silica fabric ofsufficient thickness, weight and strength such that it can be leached toincrease silica concentration and still remain strong enough forsufficient fire and pressure resistance, and become translucent ortransparent after application of a silicone resin that is refractoryindex (RI) matched to the fabric. The proper amount of combined siliconeresin 30 is dependent on the thickness, density and size of the fabricsheet 32. The combined silicone resin 30 is applied to fabric sheet 32resulting in impregnation 34 of fabric sheet 32 with combined siliconeresin 30. Impregnation 34 with combined silicone resin 30 produces anuncured composite panel 38. Use of a single coat of resin is needed toeliminate the use of blocking film or gel-coat for non-air permeabilityrequirement (UL1784). Gel coats and films are undesirable because theygenerally will lead to surface burning.

To achieve adequate translucency, the wet-out process is critical, as ismatching the refractory index of the combined silicone resin 30 to therefractory index of fabric sheet 32, which is a property resulting fromthe chemical purity and make-up of fabric sheet 32. Further, thecombined silicone resin 30 viscosity is also important, with levels at5,000 to 15,000 cps, with optimal levels at 8,000 to 10,000 cps.

Shore hardness of the combined silicone resin 30 is also important inorder to maintain flexibility of the finished composite panel. Shorehardness of combined silicone resin 30 is optimal between the durometervalues of 30 and 60. Viscosity and shore hardness of the combinedsilicone resin 30 is also critical in the creating the correct physicalproperties of the present disclosure including puncture resistance andtensile strength, which is also a key factor in the embodiment. Shorehardness can be determined with a durometer, which measures hardness.Hard plastics have high durometer readings and are made from resins withhigh shore hardness.

Cure condition requirements are important in selecting the firstsilicone resin 22 and second silicone resin 24. The resins have no flameand smoke producing properties when the composite panel 10 is exposed tohigh heat conditions. Resins with a UL 94 V-0 rating are desirable.

As shown in FIG. 2, following application of combined silicone resin 30to fabric sheet 32 is a two stage curing process that involves a softcure 40 and a hard cure 46. Uncured composite panel 38 is firstsubjected to a soft cure 40. The soft cure includes deaeration of theuncured composite panel 38 and allows solvent 20 to evaporate. Hard cure46 involves placing the soft cured composite panel 42 in an oven 44using baking racks at temperatures of 150 to 300° F. Hard cure 46eliminates the need for a gel-coat. Lower temperatures for hard curingdo not result in the necessary surface, and higher temperatures resultin yellowing of the composite panel. The hard cure is a surface curewhich gives a monolithic non-tack surface finish. The two-stage cureprocess provides three critical advantages: solvent evaporation,deaeration prior to hard cure, and elimination of the film or gel-coatresin. After the two-stage cure process composite panel 10 is complete.Composite panel 10 is flexible enough for roll-up, such that compositepanel 10 can be rolled into a tube and extended into a sheet.

The process of the present disclosure results in a composite panel 10 ofhigh purity silica. Steps in the process may include leaching a silicafabric sheet 32 in a bath of caustic acid (or otherwise obtaining aleached silica fabric sheet 32), thereby creating a silica fabric sheet32 of high purity. Leaching increases the silica content of fabric sheet32, providing higher thermal stability for fabric sheet 32 and changingthe refractory index of fabric sheet 32 while also creating void sightsin fabric sheet 32 that enhance impregnation with by combined siliconeresin 30.

The refractory index of the fabric sheet 32 is matched to siliconeresin. The refractory index of fabric sheet 32 is dependent upon theinitial grade of silica fabric sheet 32. Properties of selected highsilica fabrics that may be used in the present disclosure are listed inTable 2. Amorphous silica fabric sheet 32 may be purchased, but isfrequently between 50-80 percent silicone content. Preferably, fabricsheet 32 is leached to 90-92% silicone for optimal functionality in thepresent disclosure.

High temperature heat shrinking to pre-shrink fabric sheet 32 is animportant step in the present disclosure. Pre-shrinking preventscomposite panel 10 from cracking during exposure to a high temperaturefire.

The use of the specified type of silicone resin, as described hererin,is critical to the disclosure, as it will provide not only the properwet-out, but also provides a source of silica particles to assist instabilization of composite panel 10 at high temperature. Viscosity ofthe silicone resin and the curing process, as described herein, arecritical elements of the present disclosure. The resin may have a UL 94Vtm=0 rating, but may also have a shore hardness of 30-60, as measuredby a durometer, to ensure the composite system remains flexible, whilelower shore hardness is suboptimal. Lower shore hardness causesgumminess in composite panel 10. Silicone resin, as disclosedhereinabove, additionally provides puncture resistance in combinationwith fabric sheet 32 to produce composite panel 10. The presentdisclosure optimally utilizes a sheet lay-up process to assist not onlywith the wet-out process, but the cure process as well.

During application of combined silicone resin 30 to fabric sheet 32,combined silicone resin 30 is drawn down in accordance with standardfiberglass reinforced plastic (FRP) procedures. Fabric sheet 32 shouldhave a consistent refractory index, thickness, and weave type such thatit will become translucent to transparent when properly matched with alike refractory index resin in a draw down wet-out procedure. Fabricsheet 32 must also be strong enough to avoid breakdown at hightemperatures.

Multiple layers of combined silicone resin 30 may be stacked to buildcomposite panel 10 thickness and added strength. Combined silicone resin30 may be aggressively applied and forced into fabric sheet 32 untilwet-out is achieved.

After application of the resin to produce uncured composite panel 38,uncured composite panel 38 is soft cured 40 for deaeration and solventevaporation. Soft curing can take place at room temperature in an areaof low humidity. Following soft cure, hard cure 46 may take place,wherein hard cure 46 involves soft cured composite panel 42 being placedin an oven using baker racks at temperatures between 150 F to 300° F.Resins such as NuSil™ LS6946 form a gas tight surface in the process ofthe present disclosure which obviates a need for a high temperaturefilm, while still achieving the desired smoke screen as required byUL1784 testing. Optically clear elastomers, such as NuSil™ LS6946silicone resin, will form a tough, monolithic surface when cured.

The resulting composite panel 10 must be strong, and thermally stable,enough to withstand the fire endurance conditions of approximate 2,000°F. for at least 30 minutes, without flame penetration, as required bytests including the UL10D furnace test using the ASTM E-119 temperatureprofile for fire endurance (shown in FIG. 4). Composite panel 10 of thepresent disclosure has been demonstrated to withstand fire conditionsunder the ASTM E-119 temperature profile for fire endurance for over 2hours, as measured in a full scale test at an internationally recognizedfire test lab.

A critical property of composite panel 10 is its ability to form aceramic. Ceramification is a chemical composition change increasing thesilica purity from approximately 92 percent to 97 percent in the presentdisclosure, a reaction where polysiloxane (silicone) is converted tosilica, as generally represented in FIG. 5. Upon exposure to a hightemperature fire, ceramification begins at approximately 1100-1200° F.and reaches completion at approximately 1700° F. A high temperature fireis simulated in a controlled setting, for regulatory purposes, by ASTME-119 temperature profile for measuring fire endurance (shown in FIG.4). Ceramification of composite panel 10 occurs as a result of thecombination of the in situ fire temperature and the high purity silicareleased from the silicone fabric 414. High purity silica is criticalfor ceramification.

Recognition that the process of the present disclosure leads toceramification was a critical step in the present disclosure.Ceramification of the composite panel 10 is an unexpected result, inthat it such a result is previously unrecognized and would not beobvious to one of ordinary skill in the art at the time of theinvention. The process of the present disclosure is the first to combinea high purity silica fabric sheet 32 and high purity silicone resin andcreate a fireproof composite panel through ceramification.

During processing, fabric sheet 32 is initially in an amorphous glassphase, and when exposed to extreme heat conditions, fabric sheet 32 willbecome crystalline, a process referred to as devitrification. However,in the composite panel 10 of the present disclosure, ceramificationoccurs, which is a change in chemistry, as may be illustrated in a phasediagram known to one of ordinary skill in the art, where the chemicalcomposition of composite panel 10 shifts to a more temperature stableceramic. Plain weave fabrics, using single end filament yarns are themost adaptable for the process of the present disclosure. Fabric sheet32 produced by the acid leaching process is ideal, as the leachingremoves the sodium (Na) content, which results in a high purity silicachemical (SI02). An additional benefit of the leaching process is thatactive sights or micro-voids left from the removal of the salt compoundsenhance wet-out and provide an ideal receptacle for the silica remainsof the silicone resin.

Ceramification, like crystallization, is a product of high temperature;however, the presence of the extremely fine, high surface (highlyreactive) silica particles left behind by the silicone once organicmaterial is oxidized results in ceramification. Crystallization ofcomposite panel 10 does occur during exposure to high temperature, whichis a change in form from amorphous (liquid glass) to a bonded crystalstructure. However, ceramification also occurs in composite panel 10,where ceramification is defined as a chemical composition change, aswould be known to one of ordinary skill in the art, which may increasethe silica content from 92% to 97%.

Higher silica content in composite panel 10 results in a more thermallystable composition. Under high temperatures, highly reactive silica isreleased from the silicone and therefore available to the silica fabricbefore the crystallization occurs.

FIGS. 3A-3C illustrate the translucency achieved by the process of thepresent disclosure. Each figure shows an illustration of an object 52behind an opaque, semi-opaque or translucent or transparent sheet, toprovide a general example of the results of the present disclosure. FIG.3A includes an opaque fabric sheet 32, prior to treatment by the processof the present disclosure. As shown in FIG. 3A, object 52 is not visiblethrough the fabric sheet 32. FIG. 3B includes a semi-opaque compositepanel 50 resulting from a treatment of fabric sheet 32 with an improperviscosity resin. Object 52 is visible only as a vague outline throughthe improperly treated composite panel. FIG. 3C, however, shows thecomposite panel 10 of the present disclosure, where object 52 is clearlyvisible through composite panel 10 of the present disclosure.

FIG. 6 shows composite panel 10 incorporated into a fire curtain 70.

Use of excess resin, which will provide too much organic material, mayreduce fireproof properties of composite panel 10. Further, improperdeaeration may leave air bubbles entrapped in composite panel 10,thereby reducing bond strength as well as translucency. Additionally,insufficiency of resin will produce poor composite integrity. A curingtemperature that is too high may cause frosting and reduce translucency.

An alternative method of producing the composite panel of the presentdisclosure includes use of vacuums and pressures, applied a thermalpress, to eliminate the need for a dispersant.

Composite sheet 10 may have superior performance when translucent ratherthan when fully transparent, due to the translucent composite sheet 10having a lower temperature on an exposed side during a high temperaturefire. In testing related to the present disclosure, the exposed sidetemperature was measured for a translucent composite sheet 10 incomparison to a transparent composite sheet 10 under the sameconditions, and the translucent composite sheet 10 had a lowertemperature than the transparent composite sheet 10 by approximately20%. Under certain fire conditions and for certain applications,however, a transparent composite sheet 10 may be desirable. For example,translucency has been shown to have some advantages in radiant energyheat transfer.

While preferred embodiments of this disclosure has been described aboveand shown in the accompanying drawings, it should be understood thatapplicant does not intend to be limited to the particular detailsdescribed above and illustrated in the accompanying drawings, butintends to be limited only to the scope of the disclosure as defined bythe following claims. In this regard, the term “configured” as used inthe claims is intended to include not only the designs illustrated inthe drawings of this application and the equivalent designs discussed inthe text, but it is also intended to cover other equivalents now knownto those skilled in the art, or those equivalents which may become knownto those skilled in the art in the future.

TABLE 1 Silicone Resin Properties Optical Control RI Match 1.46 CureProperty Thermoset Appearance Translucent Work Time 2 hours ViscosityUndispersed 40,000 cP typ After Dispersed 8-10,000 cP typ Mix ProertiesSelf-deaeration Durometer Type A 30 Cure Cycle Soft Cure/RTV VariableHard Cure 150 C. 30 min Tensile Strength After Cure 675 psi Tearstrength After Cure 40 ppi Young Modulus After Cure 425 psi

TABLE 2 High Silica Fabrics Properties Grade Property VS180 VS300 WeavePlain Plain Finish Pre-shrink Heat Treated Heat Treated Yarn (tex) Warp34 × 3  68 × 3  Weft 34 × 3  68 × 3  Filment Diameter μ 6.0 6.0Thickness mm 0.25 0.45 Weight g/m2 180 300 Thread Count per cm 10.5 ×10.5 9 × 9 Tensile Strength N/2.5 190 × 190 300 × 300 Chemical Content %SiO2 95 95 % Al2O3 4 4 Other Less Than 1% Less Than 1%

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 24. (canceled)25. A flexible composite panel, comprising: a silicone resin; animpregnated fabric sheet comprised of silica; wherein the flexiblecomposite panel has a fire rating of at least 30 minutes in accordancewith an ASTM E 119 temperature profile for measuring fire endurance;wherein the flexible composite panel is at least one of translucent ortransparent; and wherein the flexible composite panel is flexible suchthat the flexible composite panel is capable of being rolled into a tubeand extended into a sheet.
 26. A flexible composite panel, comprising: asilicone resin fabricated from a silicone polymer, wherein the siliconepolymer is selected from the group consisting of polydimethylsiloxaneand polysiloxane; an impregnated fabric sheet comprised of silicaimpregnated with the silicone resin, wherein prior to impregnation, thefabric sheet is high temperature heat treated to cause shrinking;wherein the flexible composite panel has a fire rating of at least 30minutes in accordance with an ASTM E 119 temperature profile formeasuring fire endurance; wherein a visible light transmission of theflexible composite panel is at least 60 percent as measured by a set oflight meters; and wherein the flexible composite panel is flexible suchthat the flexible composite panel is capable of being rolled into a tubeand extended into a sheet.
 27. A flexible composite panel, comprising: afabric sheet comprised of silica, wherein the fabric sheet isimpregnated with at least one silicone resin; wherein the at least onesilicone resin has a refractory index value matching the refractoryindex value of the fabric sheet; wherein the flexible composite panel istranslucent to transparent.
 28. The flexible composite panel of claim27, wherein the fabric sheet is heat shrunk at a suitable temperature.29. The flexible composite panel of claim 27, wherein the flexiblecomposite panel includes a first silicone resin and a second siliconeresin; wherein the first silicone resin and the second silicone resincontain an inorganic catalyst.
 30. The flexible composite panel of claim27, wherein the at least one silicone resin has a matching refractoryindex value of 1.45 to 1.47.
 31. The flexible composite panel of claim27, wherein the fabric sheet comprises between 90 to 95 percent silica.32. The flexible composite panel of claim 27, wherein the flexiblecomposite panel has a monolithic non-tack surface finish.
 33. Theflexible composite panel of claim 29, wherein a viscosity at 25° C. of acombined first silicone resin and second silicone resin is between8,000-10,000 centipoise.
 34. The flexible composite panel of claim 27,wherein a viscosity at 25° C. of a first silicone resin is approximatelybetween 40,000 and 60,000 centipoise, and viscosity at 25° C. of asecond silicone resin is approximately 40,000-60,000 centipoise.
 35. Theflexible composite panel of claim 34, wherein a shore hardness of thecombined silicone resin is in a range from about 30 to about 60 asmeasured on a durometer.
 36. The flexible composite panel of claim 27,wherein ceramification of the flexible composite panel begins to occurat a temperature above about 1200° F. and is complete at about 1700° F.,wherein ceramification is a change in chemical composition thatincreases a silica purity from approximately 92 percent to 98 percentsilica.
 37. The flexible composite panel of claim 27, wherein theflexible composite panel has a fire rating of at least 30 minutes inaccordance with an ASTM E 119 temperature profile for measuring fireendurance.
 38. The flexible composite panel of claim 27, wherein theflexible composite panel has a fire rating of at least 2 hours inaccordance with an ASTM E 119 temperature profile for measuring fireendurance.
 39. The flexible composite panel of claim 27, wherein theflexible composite panel is capable of being rolled into a tube andextended into a sheet.
 40. The flexible composite panel of claim 27,wherein a visible light transmission of the flexible composite panel isat least 60 percent as measured by a set of light meters.
 41. Theflexible composite panel of claim 27, wherein a basis weight of thefabric sheet is between 180 and 600 gsm.
 42. The flexible compositepanel of claim 27, wherein the flexible composite panel is a coatedfabric.
 43. The flexible composite panel of claim 27, wherein theflexible composite panel comprises at least one layer of an opticallycontrolled silicone resin and the fabric sheet.
 44. The flexiblecomposite panel of claim 27, wherein the flexible composite panel is acomposite material comprised of three layers.
 45. The flexible compositepanel of claim 27, wherein the impregnated silicone fabric sheet iscentered between two layers of optically controlled silicone resin. 46.The flexible composite panel of claim 27, wherein the at least onesilicone resin is generated from silicone polymers selected from thegroup consisting of polydimethylsiloxanes and polysiloxanes.
 47. Theflexible composite panel of claim 27, wherein the flexible compositepanel comprises a treated and encapsulated silica fabric.
 48. Theflexible composite panel of claim 27, wherein the flexible compositepanel does not include a gel coat or a film.
 49. The flexible compositepanel of claim 27, wherein the flexible composite panel is adapted toform a ceramic when heated to suitable temperature.
 50. The flexiblecomposite panel of claim 27, wherein the flexible composite panel iscapable of forming a ceramic when heated to a suitable temperature,wherein the ceramic results from a chemical composition change whereby asilica purity of the flexible composite panel is increased from about 92percent to about 97 percent.